Plant Layout

Plant layout can be defined as a technique of locating machines, processes and plant
services within the factory so as to achieve the greatest possible output of high quality
at the lowest possible total cost of manufacturing.
Plant layout is a mechanism which involves knowledge of the space requirements for
the facilities and also involves their proper arrangement so that continuous and steady
movement of the production cycle takes place.
A well-designed plant layout can help a manufacturing company improve efficiency,
reduce costs, and increase productivity. It can also help ensure the quality of the
products being made.
Benefits of plant layout

•Reduced costs

•A plant layout can help reduce the cost of materials handling, labor, and manufacturing.

•Increased productivity

•A plant layout can help increase productivity by reducing bottlenecks, minimizing machine interference, and improving the utilization of
space, people, and equipment.

•Improved quality

•A plant layout can help ensure that high-quality products are being made.

•Reduced lead time

•A plant layout can help reduce the time it takes to get products from start to finish.

•Greater flexibility

•A plant layout can help make it easier to change product designs or expand production.

•Improved safety

•A plant layout can help reduce accidents and hazards by improving ergonomics and reducing noise and vibrations.

•Better customer satisfaction

•A plant layout can help improve customer satisfaction by reducing delivery failures and increasing inventory turnover.

Plant layout is a technique for arranging machines, processes, and services within a factory.
NEED FOR PLANNING AND FOLLOW UP
5.1 Need and Approach:

Need of planning for safety and health and 'safety engineering approach in design, planning and construction of
new plant or new alteration or addition' are basic and most essential, because:

1. General efficiency and safety in industrial activities can be greatly increased thereby.
2. Accidents and occupational diseases can be prevented from the earliest days.
3. Cost saving factors can be considered by effective use of floor area, providing ample space for men, materials
and machines, reducing the cost of material handling, reducing the time of work or process and making efficient
use of resources, personnel and equipment etc.
4. Efficient flow of work is maintained, and
5. Safety and comfort of people are achieved by considering ergonomic aspects.

Safety and layout engineer must take into account :

1.Products and product layout 2.Raw materials, processes and their layout
3.Size and type of site and building. 4.Machinery, vessels and equipment required.
5.Assessment of manpower required. 6.Relationship between departments.
7.Process flow chart. 8.String and flow diagrams.
9.Templates and scale models. 10.Drawings and plot plans, and
11.Travel chart etc.
Follow up :

As need for planning is important, follow up action according to that planning is equally
important. Without follow up no planning can be executed. Therefore distinct responsibilities
should be assigned to different persons to implement the follow up actions of every stage or step
decided in planning. It should be reported to the higher officer, feed back should be received for
correction or addition if any and the work should be completed within a stipulated time. All points
of safety, health, environment and ergonomic factors should be included from the built-in stage. If
this follow-up is missed in the initial stage, later follow-up may become continuous and costly.
 Minimum Dimentions :) Roof Heights (minimum required):
For RCC Slab/Tiles/False Ceiling - 12’ or 3.7 M
AC Sheet - 16’ or 4.9 M
GI Sheet - 18’ or 5.5 M
To prevent fall accidents, it is highly essential to use unbreakable metal sheet instead
of a fragile AC sheet as roofing.
Now a days, reinforced plastic sheets are available against the normal fragile AC sheets.
Fragile AC sheets are unsafe as they have caused many fatal (fall) accidents.
Minimum roof height for Canteen, Shelter, Rest room. Lunch room and Creche - 12' or 3.7 M.
(B)
B) Other Dimensions (minimum required):
1. Work Room area (Sq.M) > (No. of Workers in the room x 14.2) + Volume in cub m. of machineries
in the room

Height Of Roof (Max 4.2Meters)

. Sanitary Blocks (Sec. 19 & 42)

Latrines - 16 SF or 1.5 SM
Urinals -12 SF or 1.1SM
Bathrooms - 24 SF or 2.2 SM
No. of Latrines - As per Rule 50, The MFR 1963
For Females - 1 per 25 females
For males - 1 per 25 up to 100
- 1 per 50 thereafter.

No. of Urinals As per Rule 48 The MFR 1963

For males - 1 per 50 up to 500
- 1 per 100 thereafter.

No. of Bathrooms/Washing Places - As per Rule 74 of The MFR 1963

No. of Taps - 1 per 15 workers or as per Schedule in the Rule. At least 27.3 litres
water per worker per day is necessary.
 As per Sec 32, 38
Minimum width of fire exit 3' or 0.91 m. and minimum height 6.6' or 2m. as per Rule 66(l)(b). One or
two separate stairs necessary as per Rule 66 (l)(c) or (d). All means of access should be shown clearly.

Minimum Dimensions of Manholes : Size : 0.41 m x 0.31 m or 1.35' x 1.0' or 0.41 m or 1.35'
diameter.
Machine Distances ; Normally a distance of 3' or 1m should be kepi between a machine and the
nearest machine or a fixed structure (e.g. wall).
Dimensions of Fire Exits
An exit includes doorway, corridor and passageway but does not include lifts, escalators and
revolving doors. The exit should provide continuous (unobstructed) and safe egress (departure) by fire
resisting wall. See item 9 (24 points) in Part 3.1 of Chapter-13 for fire exits specifications.
Storage of Material
1. Passage width between two piles > 90 cm.
2. Clearance between ceiling and the pile top > 2 m.
3. Safe distance in heaps of flammable material. Open ground storage at minimum distance of
10m from process or storage building.
4. Gas cylinders should be away from highly flammable substances, furnaces and hot processes.
Roof and adequate ventilation are necessary.

Location of Fire Extinguishers

750 mm above the floor level.
Canteen (applicable for workers 250 or more) As per Sec 46 and Rule 72 & 73.
Minimum height - 12 ft. or 3.7 mt.
Minimum Area for dining hall = 1 SM or 11 SF per worker of 30% of workers working at a time.
(Area occupied by service counter and furniture except tables and chairs should be excluded).
Canteen should be at least 50 ft or 15.2 m. away from latrine, urinal, boiler house, coal stacks, ash
dumps etc.
Scrap and waste disposal in a factory involves collecting, segregating, and disposing of materials in a responsible manner. Some methods for disposing of scrap and waste
include recycling, composting, and incineration.

Scrap

•Identification: Identify faulty or substandard products

•Segregation: Separate scrap from acceptable products

•Disposal: Dispose of scrap through an authorized scrap agent

•Recycling: Recycle scrap materials, such as metals, for reuse

•Reusing: Reuse scrap products as spare parts or raw materials

•Selling: Sell scrap products as raw materials or spare parts

Waste

•Composting: Convert organic waste into fertilizer that can be used to improve soil quality

•Recycling: Recycle waste materials that can be transformed into something useful

•Incineration: Dispose of hazardous waste through high temperature incineration

•Landfilling: Dispose of waste that cannot be reused or recycled by spreading it in low-lying areas

Factors that contribute to scrap poor quality control, inefficient processes, and poor training.

Tips to reduce waste Set a waste management goal, Minimize overstocking and overproduction, Reduce packaging, and Perform a professional waste audit.
 Landfill

In this process, the waste that cannot be reused or recycled are separated out and spread as a
thin layer in low-lying areas across a city. A layer of soil is added after each layer of garbage. However,
once this process is complete, the area is declared unfit for construction of buildings for the next 20
years. Instead, it can only be used as a playground or a park.

Incineration

Incineration is the process of controlled combustion of garbage to reduce it to incombustible

matter such as ash and waste gas. The exhaust gases from this process may be toxic, hence it is
treated before being released into the environment. This process reduces the volume of waste by 90
per cent and is considered as one of the most hygienic methods of waste disposal. In some cases, the
heat generated is used to produce electricity. However, some consider this process, not quite
environmentally friendly due to the generation of greenhouse gases such as carbon dioxide and
carbon monoxide.
Waste Compaction

The waste materials such as cans and plastic bottles are compacted into blocks and sent for recycling.
This process prevents the oxidation of metals and reduces airspace need, thus making transportation
and positioning easy.

Biogas Generation

Biodegradable waste, such as food items, animal waste or organic industrial waste from food packaging
industries are sent to bio-degradation plants. In bio-degradation plants, they are converted to biogas by
degradation with the help of bacteria, fungi, or other microbes. Here, the organic matter serves as food
for the micro-organisms. The degradation can happen aerobically (with oxygen) or anaerobically (without
oxygen). Biogas is generated as a result of this process, which is used as fuel, and the residue is used as
manure.
Composting

All organic materials decompose with time. Food scraps, yard waste, etc., make up for one of the major organic
wastes we throw every day. The process of composting starts with these organic wastes being buried under layers
of soil and then, are left to decay under the action of microorganisms such as bacteria and fungi.

This results in the formation of nutrient-rich manure. Also, this process ensures that the nutrients are replenished in
the soil. Besides enriching the soil, composting also increases the water retention capacity. In agriculture, it is the
best alternative to chemical fertilizers.

Vermicomposting

Vermicomposting is the process of using worms for the degradation of organic matter into nutrient-rich manure.
Worms consume and digest the organic matter. The by-products of digestion which are excreted out by the worms
make the soil nutrient-rich, thus enhancing the growth of bacteria and fungi. It is also far more effective than
traditional composting.
To prevent spills in the workplace, you can store materials properly, maintain equipment, and train
employees. You can also have a plan in place for responding to spills.

Storage
•Store materials in the right containers and in compatible groups
•Seal materials securely
•Keep materials indoors and away from exterior doors and sewer drains
•Store hazardous materials in covered containers
•Limit the amount of hazardous materials stored
•Place materials out of the way of foot and vehicle traffic

Equipment maintenance
•Check storage equipment, material lines, and dispensing areas for leaks regularly
•Maintain and inspect equipment
•Keep containers in good shape
Training Train employees in spill prevention and cleanup and Conduct refresher training.

Spill response plan

•Post spill response procedures and emergency phone numbers in storage areas
•Have a plan for responding to spills
•Designate responsible individuals to oversee and enforce control measures

Spills
•Assess the spill to determine the type and extent of the spill
•Evacuate the area and alert others if the spill involves hazardous materials
•Contain the spill
•Stop the source of the spill
•Clean up the spill
To prevent spillage in a factory,

•Develop a spill prevention and response plan: This plan should include procedures to protect the environment and human health.

•Maintain and inspect equipment: Keep containers in good condition and regularly inspect equipment.

•Use less: Try to reduce the amount of materials used.

•Use spill control equipment: Use spill kits, absorbent powders, or sorbent socks to contain spills.

•Train employees: Conduct refresher training and employee interviews.

•Use personal protective equipment: Wear gloves and goggles to protect your hands and eyes.

In the event of a spill, you can:

•Communicate the spill

•Alert employees in the area and involve a supervisor or communications specialist to notify more people.

•Confine the spill

•Use sorbents to limit the spill area.

•Decontaminate

•Decontaminate anyone who touched the spill, including workers, clothes, products, and equipment.

•Clean up Use cleanup equipment and a professional response to reduce the costs of the spill.